US20160186675A1 - System and method for operating a diesel engine - Google Patents
System and method for operating a diesel engine Download PDFInfo
- Publication number
- US20160186675A1 US20160186675A1 US15/065,426 US201615065426A US2016186675A1 US 20160186675 A1 US20160186675 A1 US 20160186675A1 US 201615065426 A US201615065426 A US 201615065426A US 2016186675 A1 US2016186675 A1 US 2016186675A1
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- generator
- engine
- generating set
- igbt
- operable
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- 239000000446 fuel Substances 0.000 claims abstract description 16
- 230000007704 transition Effects 0.000 claims abstract description 9
- 230000008929 regeneration Effects 0.000 claims description 41
- 238000011069 regeneration method Methods 0.000 claims description 41
- 239000013618 particulate matter Substances 0.000 claims description 9
- 238000010276 construction Methods 0.000 description 28
- 125000004122 cyclic group Chemical group 0.000 description 9
- 239000004071 soot Substances 0.000 description 9
- 230000005540 biological transmission Effects 0.000 description 2
- 230000008878 coupling Effects 0.000 description 2
- 238000010168 coupling process Methods 0.000 description 2
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- 239000002828 fuel tank Substances 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 230000003197 catalytic effect Effects 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
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- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 description 1
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Images
Classifications
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- F02D29/00—Controlling engines, such controlling being peculiar to the devices driven thereby, the devices being other than parts or accessories essential to engine operation, e.g. controlling of engines by signals external thereto
- F02D29/06—Controlling engines, such controlling being peculiar to the devices driven thereby, the devices being other than parts or accessories essential to engine operation, e.g. controlling of engines by signals external thereto peculiar to engines driving electric generators
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- B60K6/42—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by the architecture of the hybrid electric vehicle
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- F02D35/00—Controlling engines, dependent on conditions exterior or interior to engines, not otherwise provided for
- F02D35/0007—Controlling engines, dependent on conditions exterior or interior to engines, not otherwise provided for using electrical feedback
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- F02D41/00—Electrical control of supply of combustible mixture or its constituents
- F02D41/20—Output circuits, e.g. for controlling currents in command coils
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
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- H02K7/1815—Rotary generators structurally associated with reciprocating piston engines
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
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- H02P9/00—Arrangements for controlling electric generators for the purpose of obtaining a desired output
- H02P9/04—Control effected upon non-electric prime mover and dependent upon electric output value of the generator
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- F02D41/029—Introducing corrections for particular conditions exterior to the engine in relation with the state of the exhaust gas treating apparatus to purge or regenerate the exhaust gas treating apparatus the exhaust gas treating apparatus being a particulate filter
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Definitions
- the present invention relates to the arrangement and operation of a diesel engine system. More particularly, the invention relates to the arrangement and operation of a diesel engine system that powers a highly cyclic load.
- Diesel engines are often used to provide an efficient and compact source of power. Diesel engines can be used in mobile applications, such as in a truck, a locomotive, a ship, or other vehicle. In addition, diesel engines are often used to provide power in stationary applications such as portable or standby generators, air compressors, pumps, and the like.
- Diesel engines are known to produce particulate emissions (soot) during operation under certain conditions.
- filters are employed to capture the soot and reduce the particulate emissions of the engine.
- the invention provides a diesel engine that includes a particulate filter in the emission stream of the diesel engine.
- the engine is arranged to drive a cyclic load and an auxiliary load.
- the auxiliary load is variable to maintain the total load on the diesel engine above a predetermined load point for 100 percent of the operating cycle of the load or to maintain the total load on the diesel engine above a second load point for between 10 percent and 40 percent of the cycle of the cyclic load.
- the second load point is higher than the first load point.
- the second load point is maintained for between 15 percent and 30 percent of the cycle of the cyclic load.
- the invention provides a power generating set that includes an engine operable in response to a flow of fuel to produce a flow of exhaust gas.
- a generator is coupled to the engine and is operable in response to operation of the engine to produce a total electrical power
- a primary load is electrically connected to the generator to receive a portion of the total electrical power
- a secondary load is selectively connected to the generator to receive a portion of the total electrical power.
- An insulated-gate bipolar transistor (IGBT) is positioned to selectively transition between a connected state and a disconnected state. The secondary load is connected to the generator when the IGBT is in the connected state and is disconnected from the generator when the IGBT is in the disconnected state.
- the invention provides a power generating set that includes a generator operable to produce a total electrical power, an engine operable in response to a flow of fuel to drive the generator and to produce a flow of exhaust gas having an exhaust gas temperature, and a particulate filter positioned to receive the flow of exhaust gas from the engine and to filter particulate matter from the exhaust gas.
- a primary load is electrically connected to the generator to receive a portion of the total electrical power, the primary load being cyclical in nature.
- a secondary load is selectively connected to the generator to selectively receive a portion of the total electrical power and a switching element is operable to selectively transition between a connected state and a disconnected state.
- the secondary load is connected to the generator when the switching element is in the connected state and is disconnected from the generator when the switching element is in the disconnected state.
- a controller is operable to vary the state of the switching element to maintain an engine parameter above a predetermined value for a predetermined portion of each cycle of the primary load to regenerate the particulate filter.
- the invention provides a method of operating a power generating set.
- the method includes operating an engine to drive a generator, generating a total electrical power during generator operation, and switching a switching element between a connected state and a disconnected state to selectively direct a portion of the total electrical power to a secondary load when the switching element is in the connected state.
- the method also includes directing the remaining total electrical power to a primary load, the primary load being cyclical in nature and regenerating a particulate filter by moving the switching element between the connected state and the disconnected state to maintain an engine parameter above a predetermined value for a predetermined portion of each cycle of the primary load.
- a power generating set in another construction, includes an engine operable in response to a flow of fuel to produce a flow of exhaust gas, a generator coupled to the engine and operable in response to operation of the engine to produce a total electrical power, and a primary load electrically connected to the generator to receive a portion of the total electrical power, the primary load having a cyclical pattern.
- a battery bank is selectively connected to the generator to receive a portion of the total electrical power and an insulated-gate bipolar transistor (IGBT) is positioned to selectively transition between a connected state and a disconnected state.
- the battery bank is connected to the generator to charge the battery bank when the IGBT is in the connected state and is disconnected from the generator when the IGBT is in the disconnected state.
- a power generating set includes a generator operable to produce electrical power, an engine operable in response to a flow of fuel to drive the generator and to produce a flow of exhaust gas having an exhaust gas temperature, and a particulate filter positioned to receive the flow of exhaust gas from the engine and to filter particulate matter from the exhaust gas.
- a primary load is electrically connected to the generator to draw a first portion of electrical power from the generator, the primary load having a cyclical pattern and a battery bank is selectively connected to the generator to selectively draw a second portion of electrical power.
- a switching element is operable to selectively transition between a connected state and a disconnected state, wherein the battery bank is connected to the generator when the switching element is in the connected state and is disconnected from the generator when the switching element is in the disconnected state.
- a controller is operable to vary the state of the switching element to maintain the sum of the first portion of electrical power and the second portion of electrical power above a predetermined value for a predetermined portion of each cycle of the primary load such that the heat from the flow of exhaust is sufficient to one of passively regenerate or actively regenerate the particulate filter.
- a power generating set includes a generator operable to produce a total electrical power, an engine operable in response to a flow of fuel to drive the generator and to produce a flow of exhaust gas having an exhaust gas temperature, a particulate filter positioned to receive the flow of exhaust gas from the engine and to filter particulate matter from the exhaust gas, and a primary load electrically connected to the generator to receive a first portion of the total electrical power that varies in a series of cycles between a maximum that is above a predetermined value and a minimum that is below a predetermined value.
- a battery bank is electrically connected to the generator to receive a second portion of the total electrical power, and a switching element is operable to selectively transition between a connected state and a disconnected state, wherein the battery bank is connected to the generator when the switching element is in the connected state and is disconnected from the generator when the switching element is in the disconnected state.
- a controller is operable to vary the state of the switching element to maintain the sum of the first portion of the total electrical power and the second portion of the total electric power above the predetermined value for a portion of each cycle, the portion of each cycle being sufficient to one of passively regenerate or actively regenerate the particulate filter.
- FIG. 1 is a schematic illustration of a diesel powered generator system
- FIG. 2 is a flow chart illustrating a control scheme for the diesel powered generator system of FIG. 1 ;
- FIG. 3 is a flow chart illustrating another control scheme for the diesel powered generator system of FIG. 1 ;
- FIG. 4 is a graphical representation of a cyclic load and two possible auxiliary loads
- FIG. 5 is a schematic illustration of another diesel powered generator system.
- FIG. 6 is a graphical representation of the predetermined value for active regeneration versus ambient temperature.
- FIG. 1 illustrates a system 10 that includes a diesel engine 15 that drives a generator 20 .
- the generator 20 is a three-phase AC generator 20 that is rotated at a desired speed to provide a three-phase current at a desired voltage (e.g., 480 volts) and a desired frequency (e.g., 60 Hz).
- a desired voltage e.g., 480 volts
- a desired frequency e.g. 60 Hz
- asynchronous generators, synchronous generators, single-phase AC and DC generators or any other type of generator is powered by the diesel engine 15 .
- the diesel engine 15 includes a fuel tank 25 and a particulate filter 30 positioned in an exhaust stream 35 of the diesel engine 15 .
- the fuel tank 25 contains a fuel supply that is directed to the engine 15 and combusted with a flow of air 40 to produce shaft power and the exhaust stream 35 .
- the exhaust stream 35 includes a quantity of particulate matter (sometimes referred to as soot) that is preferably filtered rather than being emitted into the atmosphere.
- the quantity of particulate matter emitted is a function of the operating temperature of the engine 15 , and in particular the exhaust temperature of the engine 15 , with higher operating temperatures significantly reducing the amount of soot produced by the engine 15 .
- the load on the engine 15 , the generator 20 , and the exhaust temperature of the engine 15 are closely related in this example and are used interchangeably herein.
- the diesel engine 15 is at a high temperature when operated at a high generator load and is at a low temperature when operated at a low load.
- the particulate filter 30 includes any type of commonly used in-flow particulate filters for use with diesel engines 15 .
- the particulate filter 30 may include filters made using cordierite, silicon carbide, other ceramic fibers, or metal fibers that are arranged or woven to capture particles as the exhaust stream 35 flows through the filter.
- the particulate filter 30 may include a catalytic material that aids in the regeneration of the filter 30 .
- the filter 30 is capable of both passive and active regeneration.
- Passive filter regeneration occurs when the load on the diesel engine 15 and therefore the exhaust temperature exceeds a temperature threshold 45 . Above this level, sufficient energy is present within the filter 30 to oxidize the soot and other particulate matter collected.
- the duration required above the temperature threshold 45 is a function of the quantity of soot captured in the filter 30 .
- Active regeneration occurs and must be used when the engine 15 is operated at a load or exhaust temperature that remains below a level where passive regeneration can occur.
- fuel is passed to the particulate filter 30 to increase the available energy and therefore the temperature within the filter 30 to aid in the combustion of the soot particles.
- regeneration is not effective if performed below the predetermined level 50 .
- the load or temperature must remain above the predetermined level 50 for all or substantially all (greater than 90 percent) of the operating cycle of the load applied to the engine 15 in order for active regeneration to be effective.
- the three phase power produced by the generator 20 is directed to a voltage selector switch 54 and then to a main circuit breaker 55 that can be manually controlled, automatically controlled, or both and is operable to separate the generator 20 from a total load 60 that is connected to an output side of the main breaker 55 .
- the voltage selector switch allows the user to select the output voltage of the generator 20 .
- the total load 60 is divided into a main load 65 and an auxiliary load 70 .
- the generator 20 is capable of driving virtually any electrical load
- the invention is particularly advantageous when the main load 65 is highly cyclical.
- generator systems of the type illustrated in FIG. 1 are often used to provide electrical power to motor driven pump jacks.
- the motor is often the sole load or virtually the sole load such that the main load 65 follows a cyclic pattern.
- the auxiliary load 70 is applied to the generator 20 in parallel with the main load 65 .
- the auxiliary load 70 includes one or more switching elements 75 connected to an electrical load 80 .
- the switching elements 75 include a single insulated-gate bipolar transistor (IGBT) that facilitates rapid switching to direct power to the electrical load 80 or to inhibit the flow of power to the electrical load 80 .
- the electrical load 80 includes one or more resistors that can be switched on and off individually or in groups.
- the illustrated arrangement provides fine control of the size of the auxiliary load 70 and can provide rapid and smooth changes in that size as will be discussed in greater detail.
- FIG. 2 illustrates a three phase DC power supply 82 positioned between the main circuit breaker 55 and the switching elements 75 .
- the switching element is an IGBT 75 that operates using DC power.
- the power supply 82 operates to convert the three phase AC power produced by the generator 20 to a single phase DC supply usable by the IGBT 75 .
- AC switching elements may be employed, thereby eliminating the need for the DC power supply 82 .
- the generator 20 produces a three phase output of electrical current at a desired voltage.
- An engine control system 85 operates to maintain the engine speed at the speed required to drive the generator 20 at the desired speed.
- the diesel engine 15 rotates at the same speed as the generator 20 .
- a transmission is positioned between the generator 20 and the engine 15 to either step up or step down the speed of the generator 20 with respect to the engine 15 .
- a controller 90 is coupled to the IGBT 75 and is operable to control the state of the IGBT 75 to control the level of the auxiliary load 70 .
- the controller 90 adjusts the auxiliary load 70 via the IGBT 75 to maintain a level total load 60 on the generator 20 or to produce a peak load on the generator 20 as will be discussed with regard to FIG. 4 .
- the controller 90 applies a pulse width modulation signal to the single IGBT 75 to turn it on for a predetermined portion of a period of time. When on, the full auxiliary load 80 is electrically connected to the generator 20 .
- the controller 90 By pulsing the IGBT 75 on and off, the controller 90 is able to precisely control the average power consumed during the period of time to provide very fine control of the size of the auxiliary load 80 . For example, if during a given time period (e.g., 1 second), a total resistive load 80 is applied via the IGBT 75 for half of the time period, the total resistive load applied to the generator 20 will effectively be half the load's actual size.
- a given time period e.g. 1 second
- the IGBT 75 is replaced by a number of switching elements and the load 80 includes a plurality of individual loads each switchable via one of the switching elements. During operation, select switching elements are switched to connect a respective load to achieve a desired auxiliary load level.
- the engine electronic control module (ECM) 85 senses the speed or the load of the engine 15 and controls a fuel throttle valve to adjust the speed or load of the engine 15 as is known in the art.
- the ECM 85 provides one or more inputs to the controller 90 for use in setting the auxiliary load level 70 .
- the ECM 85 determines a total load on the engine 15 and sends a signal indicative of that load to the controller 90 .
- the controller 90 then adjusts the auxiliary load level 70 until the engine load is above a predetermined level.
- other parameters e.g., exhaust temperature, engine temperature, fuel flow rate, exhaust pressure, inlet pressure, etc.
- yet another construction measures the current and voltage of the generator output to determine the total electrical power generated.
- the auxiliary load level 70 is easily measured, thereby allowing for a direct calculation of the main load level.
- some parameters collected by the ECM 85 can be used to verify that the filter regeneration is effective. For example, one construction monitors the pressure drop across the filter 30 and adjusts the temperature, the time, the engine load, or other parameters of the operation in response to the measured pressure. In one arrangement, if the pressure drop exceeds a predetermined threshold, the time above the temperature threshold 45 is increased during passive regeneration and/or the predetermined level 50 for active regeneration is increased until the pressure drop returns to normal.
- FIG. 3 illustrates another system that is similar to the system of FIG. 2 but includes a current sensor 95 .
- the current sensor 95 does not replace the ECM 85 of FIG. 2 but rather is used to collect data that is then delivered to the controller 90 to control the IGBT 75 .
- the current sensor 95 senses the level of power flowing to the main load 65 and feeds that information to the controller 90 .
- the controller 90 then adjusts the pulse width to the IGBT 75 as required to achieve the desired level of total power 60 consumed.
- a temperature probe is placed in the engine exhaust flow 35 to measure the exhaust gas temperature. The temperature signal is then delivered to the controller 90 and the IGBT 75 is adjusted to raise or lower the auxiliary load 70 and the temperature as desired.
- FIG. 4 is a graph of percent engine/generator load or percent exhaust temperature (with 0% being room temperature and 100% being the maximum exhaust temperature) versus time.
- the vertical broken lines identify the start 100 of and the end 105 of one pump jack cycle.
- a first horizontal broken line marks the lower threshold for passive regeneration 45 and a second horizontal line indicates the predetermined value for active regeneration 50 .
- pump jacks rotate through a cycle that includes a first portion that requires a large power input followed by a second portion during which little or no power is required.
- the motor is heavily loaded and thus draws a significant load from the generator 20 .
- the pump jack consumes an average amount of power during its cycle.
- the motor and generator 20 powering these pump jacks are often sized to deliver significantly more than the average power level to assure that the components are capable of providing the power required in the first portion of the cycle. Because the pump jack is virtually the entire load on the generator 20 , the diesel engine power output follows the pump jack curve and moves through a cycle with a short-time high-load peak followed by a low-load portion where the diesel engine 15 virtually coasts.
- the pump jack cycle includes a short spike (about 20 percent of the cycle) that exceeds the predetermined level 50 for active regeneration but falls short of the threshold value 45 for passive regeneration. The load then drops below the predetermined level 50 for the remainder of the cycle. As discussed above, this cycle does not allow for passive regeneration, nor does it allow for effective active regeneration.
- the controller 90 can be programmed to achieve either passive regeneration, active regeneration or both using the auxiliary load 70 .
- the controller 90 signals the IGBT 75 to add auxiliary load 70 during the peak load of the cycle.
- the added load indicated by the first cross-hatched region 110 of FIG. 4 assures that the total load 60 on the diesel engine 15 exceeds the threshold level 45 for the necessary time or portion of the cycle to achieve passive regeneration.
- the auxiliary load 70 is then smoothly switched off and the total load 60 is allowed to drop to the lower level.
- the controller 90 monitors the total load 60 on the generator 20 or the engine 15 and signals the IGBT 75 to add auxiliary load 70 , shown as the second cross-hatched region 115 , where needed to assure that the minimum total load 60 always remains above the predetermined level 50 .
- the engine operation is also modified to assure that some fuel passes to the particulate filter 30 as is required for active regeneration.
- the controller 90 uses both active and passive regeneration by adding load as necessary and as described with regard to the individual modes of regeneration.
- the engine control module can be used to determine when and how frequently regeneration must occur as well as which type of regeneration to perform if desired.
- FIG. 6 graphically illustrates how ambient temperature can effect regeneration and specifically the value or percent load of the predetermined value 50 for active regeneration.
- filter manufacturers recommend operation above a predetermined value 50 for active regeneration that is based on the lowest possible ambient temperature. However, in warmer ambient conditions, this can be a significant and excessive load on the engine 15 . Thus, some constructions will vary the predetermined value 50 for active regeneration as illustrated in FIG. 6 based on a measured ambient temperature.
- loads 80 as well as other switching elements 75 could be employed if desired.
- batteries could be used in place of resistors to provide a load.
- FIG. 5 illustrates an alternative construction 117 in which the large generator 20 is replaced by the load which is mechanically driven by the diesel engine 15 .
- the load may be the transmission or drive system of a vehicle.
- a smaller generator 120 is simultaneously driven by the diesel engine 15 , via a belt, gear, chain, or other interconnecting arrangement to provide an electrical current to an auxiliary load 70 that is similar to that described above.
- the auxiliary load 70 is switched in and out as described with regard to FIG. 4 to achieve the desired regeneration.
- the auxiliary load 70 is used to increase the total load 60 on the engine 15 as required to achieve either passive or active regeneration. Regeneration is largely a function of the temperature of the exhaust gas 35 entering the filter 30 .
- the invention controls engine load and may measure various different engine or system parameters, those parameters are related to the engine exhaust temperature.
- the performance of the system is further enhanced by placing the resistive load 80 directly in the exhaust flow stream 35 or adjacent the exhaust flow stream 35 to allow the heat produced by the resistors 80 to directly or indirectly heat the exhaust flow 35 , thereby reducing the amount of auxiliary load 70 required to reach the predetermined level 50 or the temperature threshold 45 .
Abstract
Description
- This application is a continuation of U.S. application Ser. No. 14/267,975 filed May 2, 2014, now U.S. Pat. No. X,XXX,XXX, which claims priority to U.S. Provisional Application No. 61/818,532 filed May 2, 2013, the entire contents of each are incorporated herein by reference.
- The present invention relates to the arrangement and operation of a diesel engine system. More particularly, the invention relates to the arrangement and operation of a diesel engine system that powers a highly cyclic load.
- Diesel engines are often used to provide an efficient and compact source of power. Diesel engines can be used in mobile applications, such as in a truck, a locomotive, a ship, or other vehicle. In addition, diesel engines are often used to provide power in stationary applications such as portable or standby generators, air compressors, pumps, and the like.
- Diesel engines are known to produce particulate emissions (soot) during operation under certain conditions. In some applications, filters are employed to capture the soot and reduce the particulate emissions of the engine.
- In one construction, the invention provides a diesel engine that includes a particulate filter in the emission stream of the diesel engine. The engine is arranged to drive a cyclic load and an auxiliary load. The auxiliary load is variable to maintain the total load on the diesel engine above a predetermined load point for 100 percent of the operating cycle of the load or to maintain the total load on the diesel engine above a second load point for between 10 percent and 40 percent of the cycle of the cyclic load. The second load point is higher than the first load point. In preferred constructions, the second load point is maintained for between 15 percent and 30 percent of the cycle of the cyclic load.
- In one construction, the invention provides a power generating set that includes an engine operable in response to a flow of fuel to produce a flow of exhaust gas. A generator is coupled to the engine and is operable in response to operation of the engine to produce a total electrical power, a primary load is electrically connected to the generator to receive a portion of the total electrical power, and a secondary load is selectively connected to the generator to receive a portion of the total electrical power. An insulated-gate bipolar transistor (IGBT) is positioned to selectively transition between a connected state and a disconnected state. The secondary load is connected to the generator when the IGBT is in the connected state and is disconnected from the generator when the IGBT is in the disconnected state.
- In another construction, the invention provides a power generating set that includes a generator operable to produce a total electrical power, an engine operable in response to a flow of fuel to drive the generator and to produce a flow of exhaust gas having an exhaust gas temperature, and a particulate filter positioned to receive the flow of exhaust gas from the engine and to filter particulate matter from the exhaust gas. A primary load is electrically connected to the generator to receive a portion of the total electrical power, the primary load being cyclical in nature. A secondary load is selectively connected to the generator to selectively receive a portion of the total electrical power and a switching element is operable to selectively transition between a connected state and a disconnected state. The secondary load is connected to the generator when the switching element is in the connected state and is disconnected from the generator when the switching element is in the disconnected state. A controller is operable to vary the state of the switching element to maintain an engine parameter above a predetermined value for a predetermined portion of each cycle of the primary load to regenerate the particulate filter.
- In yet another construction, the invention provides a method of operating a power generating set. The method includes operating an engine to drive a generator, generating a total electrical power during generator operation, and switching a switching element between a connected state and a disconnected state to selectively direct a portion of the total electrical power to a secondary load when the switching element is in the connected state. The method also includes directing the remaining total electrical power to a primary load, the primary load being cyclical in nature and regenerating a particulate filter by moving the switching element between the connected state and the disconnected state to maintain an engine parameter above a predetermined value for a predetermined portion of each cycle of the primary load.
- In another construction, a power generating set includes an engine operable in response to a flow of fuel to produce a flow of exhaust gas, a generator coupled to the engine and operable in response to operation of the engine to produce a total electrical power, and a primary load electrically connected to the generator to receive a portion of the total electrical power, the primary load having a cyclical pattern. A battery bank is selectively connected to the generator to receive a portion of the total electrical power and an insulated-gate bipolar transistor (IGBT) is positioned to selectively transition between a connected state and a disconnected state. The battery bank is connected to the generator to charge the battery bank when the IGBT is in the connected state and is disconnected from the generator when the IGBT is in the disconnected state.
- In yet another construction, a power generating set includes a generator operable to produce electrical power, an engine operable in response to a flow of fuel to drive the generator and to produce a flow of exhaust gas having an exhaust gas temperature, and a particulate filter positioned to receive the flow of exhaust gas from the engine and to filter particulate matter from the exhaust gas. A primary load is electrically connected to the generator to draw a first portion of electrical power from the generator, the primary load having a cyclical pattern and a battery bank is selectively connected to the generator to selectively draw a second portion of electrical power. A switching element is operable to selectively transition between a connected state and a disconnected state, wherein the battery bank is connected to the generator when the switching element is in the connected state and is disconnected from the generator when the switching element is in the disconnected state. A controller is operable to vary the state of the switching element to maintain the sum of the first portion of electrical power and the second portion of electrical power above a predetermined value for a predetermined portion of each cycle of the primary load such that the heat from the flow of exhaust is sufficient to one of passively regenerate or actively regenerate the particulate filter.
- In still another construction, a power generating set includes a generator operable to produce a total electrical power, an engine operable in response to a flow of fuel to drive the generator and to produce a flow of exhaust gas having an exhaust gas temperature, a particulate filter positioned to receive the flow of exhaust gas from the engine and to filter particulate matter from the exhaust gas, and a primary load electrically connected to the generator to receive a first portion of the total electrical power that varies in a series of cycles between a maximum that is above a predetermined value and a minimum that is below a predetermined value. A battery bank is electrically connected to the generator to receive a second portion of the total electrical power, and a switching element is operable to selectively transition between a connected state and a disconnected state, wherein the battery bank is connected to the generator when the switching element is in the connected state and is disconnected from the generator when the switching element is in the disconnected state. A controller is operable to vary the state of the switching element to maintain the sum of the first portion of the total electrical power and the second portion of the total electric power above the predetermined value for a portion of each cycle, the portion of each cycle being sufficient to one of passively regenerate or actively regenerate the particulate filter.
- Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
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FIG. 1 is a schematic illustration of a diesel powered generator system; -
FIG. 2 is a flow chart illustrating a control scheme for the diesel powered generator system ofFIG. 1 ; -
FIG. 3 is a flow chart illustrating another control scheme for the diesel powered generator system ofFIG. 1 ; -
FIG. 4 is a graphical representation of a cyclic load and two possible auxiliary loads; -
FIG. 5 is a schematic illustration of another diesel powered generator system; and -
FIG. 6 is a graphical representation of the predetermined value for active regeneration versus ambient temperature. - Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
-
FIG. 1 illustrates asystem 10 that includes adiesel engine 15 that drives agenerator 20. In the illustrated construction, thegenerator 20 is a three-phase AC generator 20 that is rotated at a desired speed to provide a three-phase current at a desired voltage (e.g., 480 volts) and a desired frequency (e.g., 60 Hz). In other constructions, asynchronous generators, synchronous generators, single-phase AC and DC generators or any other type of generator is powered by thediesel engine 15. - The
diesel engine 15 includes afuel tank 25 and aparticulate filter 30 positioned in anexhaust stream 35 of thediesel engine 15. Thefuel tank 25 contains a fuel supply that is directed to theengine 15 and combusted with a flow ofair 40 to produce shaft power and theexhaust stream 35. Theexhaust stream 35 includes a quantity of particulate matter (sometimes referred to as soot) that is preferably filtered rather than being emitted into the atmosphere. The quantity of particulate matter emitted is a function of the operating temperature of theengine 15, and in particular the exhaust temperature of theengine 15, with higher operating temperatures significantly reducing the amount of soot produced by theengine 15. The load on theengine 15, thegenerator 20, and the exhaust temperature of theengine 15 are closely related in this example and are used interchangeably herein. Thus, as described in this application, thediesel engine 15 is at a high temperature when operated at a high generator load and is at a low temperature when operated at a low load. - The
particulate filter 30 includes any type of commonly used in-flow particulate filters for use withdiesel engines 15. For example, theparticulate filter 30 may include filters made using cordierite, silicon carbide, other ceramic fibers, or metal fibers that are arranged or woven to capture particles as theexhaust stream 35 flows through the filter. Theparticulate filter 30 may include a catalytic material that aids in the regeneration of thefilter 30. Preferably, thefilter 30 is capable of both passive and active regeneration. - Passive filter regeneration occurs when the load on the
diesel engine 15 and therefore the exhaust temperature exceeds atemperature threshold 45. Above this level, sufficient energy is present within thefilter 30 to oxidize the soot and other particulate matter collected. The duration required above thetemperature threshold 45 is a function of the quantity of soot captured in thefilter 30. Through extensive testing, it has been discovered that when powering a highly cyclic load such as the pump jack example described below, exceeding the threshold for between 10 percent and 30 percent of each cycle is sufficient to regenerate thefilter 30 and remove the soot collected during the prior cycle. In a preferred condition, thetemperature threshold 45 must be exceeded for only 20 percent of the total cycle. Thus, each cycle can regenerate thefilter 30 and remove any soot collected during the prior cycle. - Active regeneration occurs and must be used when the
engine 15 is operated at a load or exhaust temperature that remains below a level where passive regeneration can occur. During active regeneration, fuel is passed to theparticulate filter 30 to increase the available energy and therefore the temperature within thefilter 30 to aid in the combustion of the soot particles. While some regeneration occurs when the load or exhaust temperature is above apredetermined level 50, testing has shown that regeneration is not effective if performed below the predeterminedlevel 50. In fact, when powering a highly cyclic load such as the pump jack described below, testing has shown that the load or temperature must remain above the predeterminedlevel 50 for all or substantially all (greater than 90 percent) of the operating cycle of the load applied to theengine 15 in order for active regeneration to be effective. - In the construction of
FIG. 2 , the three phase power produced by thegenerator 20 is directed to avoltage selector switch 54 and then to amain circuit breaker 55 that can be manually controlled, automatically controlled, or both and is operable to separate thegenerator 20 from atotal load 60 that is connected to an output side of themain breaker 55. The voltage selector switch allows the user to select the output voltage of thegenerator 20. - As illustrated in
FIG. 1 , thetotal load 60 is divided into amain load 65 and anauxiliary load 70. While thegenerator 20 is capable of driving virtually any electrical load, the invention is particularly advantageous when themain load 65 is highly cyclical. For example, generator systems of the type illustrated inFIG. 1 are often used to provide electrical power to motor driven pump jacks. In these arrangements, the motor is often the sole load or virtually the sole load such that themain load 65 follows a cyclic pattern. - As illustrated in
FIG. 1 , theauxiliary load 70 is applied to thegenerator 20 in parallel with themain load 65. As illustrated inFIGS. 2 and 3 , theauxiliary load 70 includes one ormore switching elements 75 connected to anelectrical load 80. In the illustrated construction, the switchingelements 75 include a single insulated-gate bipolar transistor (IGBT) that facilitates rapid switching to direct power to theelectrical load 80 or to inhibit the flow of power to theelectrical load 80. In the illustrated construction, theelectrical load 80 includes one or more resistors that can be switched on and off individually or in groups. Thus, the illustrated arrangement provides fine control of the size of theauxiliary load 70 and can provide rapid and smooth changes in that size as will be discussed in greater detail. -
FIG. 2 illustrates a three phaseDC power supply 82 positioned between themain circuit breaker 55 and theswitching elements 75. In the preferred construction, the switching element is anIGBT 75 that operates using DC power. Thus, thepower supply 82 operates to convert the three phase AC power produced by thegenerator 20 to a single phase DC supply usable by theIGBT 75. In other constructions, AC switching elements may be employed, thereby eliminating the need for theDC power supply 82. - As noted above, the
generator 20 produces a three phase output of electrical current at a desired voltage. Anengine control system 85 operates to maintain the engine speed at the speed required to drive thegenerator 20 at the desired speed. In a direct drive arrangement, thediesel engine 15 rotates at the same speed as thegenerator 20. In some arrangements, a transmission is positioned between thegenerator 20 and theengine 15 to either step up or step down the speed of thegenerator 20 with respect to theengine 15. - With reference to
FIG. 2 , acontroller 90 is coupled to theIGBT 75 and is operable to control the state of theIGBT 75 to control the level of theauxiliary load 70. Thecontroller 90 adjusts theauxiliary load 70 via theIGBT 75 to maintain a leveltotal load 60 on thegenerator 20 or to produce a peak load on thegenerator 20 as will be discussed with regard toFIG. 4 . In a preferred construction, thecontroller 90 applies a pulse width modulation signal to thesingle IGBT 75 to turn it on for a predetermined portion of a period of time. When on, the fullauxiliary load 80 is electrically connected to thegenerator 20. By pulsing theIGBT 75 on and off, thecontroller 90 is able to precisely control the average power consumed during the period of time to provide very fine control of the size of theauxiliary load 80. For example, if during a given time period (e.g., 1 second), a totalresistive load 80 is applied via theIGBT 75 for half of the time period, the total resistive load applied to thegenerator 20 will effectively be half the load's actual size. - In another construction, the
IGBT 75 is replaced by a number of switching elements and theload 80 includes a plurality of individual loads each switchable via one of the switching elements. During operation, select switching elements are switched to connect a respective load to achieve a desired auxiliary load level. - In the construction illustrated in
FIG. 2 the engine electronic control module (ECM) 85 senses the speed or the load of theengine 15 and controls a fuel throttle valve to adjust the speed or load of theengine 15 as is known in the art. In addition, theECM 85 provides one or more inputs to thecontroller 90 for use in setting theauxiliary load level 70. For example, in one construction theECM 85 determines a total load on theengine 15 and sends a signal indicative of that load to thecontroller 90. Thecontroller 90 then adjusts theauxiliary load level 70 until the engine load is above a predetermined level. In other constructions, other parameters (e.g., exhaust temperature, engine temperature, fuel flow rate, exhaust pressure, inlet pressure, etc.) are used to control the auxiliary load level. For example, yet another construction measures the current and voltage of the generator output to determine the total electrical power generated. Theauxiliary load level 70 is easily measured, thereby allowing for a direct calculation of the main load level. - In addition, some parameters collected by the
ECM 85 can be used to verify that the filter regeneration is effective. For example, one construction monitors the pressure drop across thefilter 30 and adjusts the temperature, the time, the engine load, or other parameters of the operation in response to the measured pressure. In one arrangement, if the pressure drop exceeds a predetermined threshold, the time above thetemperature threshold 45 is increased during passive regeneration and/or thepredetermined level 50 for active regeneration is increased until the pressure drop returns to normal. -
FIG. 3 illustrates another system that is similar to the system ofFIG. 2 but includes acurrent sensor 95. Thecurrent sensor 95 does not replace theECM 85 ofFIG. 2 but rather is used to collect data that is then delivered to thecontroller 90 to control theIGBT 75. In the arrangement ofFIG. 3 , thecurrent sensor 95 senses the level of power flowing to themain load 65 and feeds that information to thecontroller 90. Thecontroller 90 then adjusts the pulse width to theIGBT 75 as required to achieve the desired level oftotal power 60 consumed. In still another construction, a temperature probe is placed in theengine exhaust flow 35 to measure the exhaust gas temperature. The temperature signal is then delivered to thecontroller 90 and theIGBT 75 is adjusted to raise or lower theauxiliary load 70 and the temperature as desired. - With reference to
FIG. 4 , the operation of the diesel drivengenerator system 10 for use in powering a highly cyclic load, in this example a pump jack, will be described.FIG. 4 is a graph of percent engine/generator load or percent exhaust temperature (with 0% being room temperature and 100% being the maximum exhaust temperature) versus time. The vertical broken lines identify the start 100 of and theend 105 of one pump jack cycle. A first horizontal broken line marks the lower threshold forpassive regeneration 45 and a second horizontal line indicates the predetermined value foractive regeneration 50. - As illustrated in
FIG. 4 , pump jacks rotate through a cycle that includes a first portion that requires a large power input followed by a second portion during which little or no power is required. During this first portion of the cycle, the motor is heavily loaded and thus draws a significant load from thegenerator 20. However, during the second portion of the cycle, very little electrical current is required. Thus, the pump jack consumes an average amount of power during its cycle. The motor andgenerator 20 powering these pump jacks are often sized to deliver significantly more than the average power level to assure that the components are capable of providing the power required in the first portion of the cycle. Because the pump jack is virtually the entire load on thegenerator 20, the diesel engine power output follows the pump jack curve and moves through a cycle with a short-time high-load peak followed by a low-load portion where thediesel engine 15 virtually coasts. - As can be seen, the pump jack cycle includes a short spike (about 20 percent of the cycle) that exceeds the predetermined
level 50 for active regeneration but falls short of thethreshold value 45 for passive regeneration. The load then drops below the predeterminedlevel 50 for the remainder of the cycle. As discussed above, this cycle does not allow for passive regeneration, nor does it allow for effective active regeneration. - The
controller 90 can be programmed to achieve either passive regeneration, active regeneration or both using theauxiliary load 70. To achieve passive generation, thecontroller 90 signals theIGBT 75 to addauxiliary load 70 during the peak load of the cycle. The added load, indicated by the firstcross-hatched region 110 ofFIG. 4 assures that thetotal load 60 on thediesel engine 15 exceeds thethreshold level 45 for the necessary time or portion of the cycle to achieve passive regeneration. Theauxiliary load 70 is then smoothly switched off and thetotal load 60 is allowed to drop to the lower level. - To achieve active regeneration, the
controller 90 monitors thetotal load 60 on thegenerator 20 or theengine 15 and signals theIGBT 75 to addauxiliary load 70, shown as the secondcross-hatched region 115, where needed to assure that the minimumtotal load 60 always remains above the predeterminedlevel 50. The engine operation is also modified to assure that some fuel passes to theparticulate filter 30 as is required for active regeneration. - In some constructions, the
controller 90 uses both active and passive regeneration by adding load as necessary and as described with regard to the individual modes of regeneration. In addition, the engine control module can be used to determine when and how frequently regeneration must occur as well as which type of regeneration to perform if desired. -
FIG. 6 graphically illustrates how ambient temperature can effect regeneration and specifically the value or percent load of thepredetermined value 50 for active regeneration. Typically, filter manufacturers recommend operation above apredetermined value 50 for active regeneration that is based on the lowest possible ambient temperature. However, in warmer ambient conditions, this can be a significant and excessive load on theengine 15. Thus, some constructions will vary thepredetermined value 50 for active regeneration as illustrated inFIG. 6 based on a measured ambient temperature. - It should be noted that other types of
loads 80 as well as other switchingelements 75 could be employed if desired. For example, batteries could be used in place of resistors to provide a load. -
FIG. 5 illustrates analternative construction 117 in which thelarge generator 20 is replaced by the load which is mechanically driven by thediesel engine 15. For example, the load may be the transmission or drive system of a vehicle. Asmaller generator 120 is simultaneously driven by thediesel engine 15, via a belt, gear, chain, or other interconnecting arrangement to provide an electrical current to anauxiliary load 70 that is similar to that described above. Theauxiliary load 70 is switched in and out as described with regard toFIG. 4 to achieve the desired regeneration. - As discussed above, the
auxiliary load 70 is used to increase thetotal load 60 on theengine 15 as required to achieve either passive or active regeneration. Regeneration is largely a function of the temperature of theexhaust gas 35 entering thefilter 30. Thus, while the invention controls engine load and may measure various different engine or system parameters, those parameters are related to the engine exhaust temperature. In one construction, the performance of the system is further enhanced by placing theresistive load 80 directly in theexhaust flow stream 35 or adjacent theexhaust flow stream 35 to allow the heat produced by theresistors 80 to directly or indirectly heat theexhaust flow 35, thereby reducing the amount ofauxiliary load 70 required to reach thepredetermined level 50 or thetemperature threshold 45. - Various features and advantages of the invention are set forth in the following claims.
Claims (19)
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US15/065,426 US10018126B2 (en) | 2013-05-02 | 2016-03-09 | System and method for operating a diesel engine |
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US201361818532P | 2013-05-02 | 2013-05-02 | |
US14/267,975 US9308910B2 (en) | 2013-05-02 | 2014-05-02 | System and method for operating a diesel engine |
US15/065,426 US10018126B2 (en) | 2013-05-02 | 2016-03-09 | System and method for operating a diesel engine |
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US14/267,975 Continuation US9308910B2 (en) | 2013-05-02 | 2014-05-02 | System and method for operating a diesel engine |
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US15/065,426 Active 2034-06-03 US10018126B2 (en) | 2013-05-02 | 2016-03-09 | System and method for operating a diesel engine |
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US10233768B1 (en) * | 2018-03-22 | 2019-03-19 | Florida Turbine Technologies, Inc. | Apparatus and process for optimizing turbine engine performance via load control through a power control module |
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WO2014179641A1 (en) | 2013-05-02 | 2014-11-06 | Clark Equipment Company | System and method for operating a diesel engine |
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JP7079725B2 (en) * | 2018-06-30 | 2022-06-02 | 株式会社クボタ | Engine work machine |
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EP2992197A1 (en) | 2016-03-09 |
US10018126B2 (en) | 2018-07-10 |
WO2014179641A1 (en) | 2014-11-06 |
EP2992197A4 (en) | 2017-01-11 |
US20140327248A1 (en) | 2014-11-06 |
US9308910B2 (en) | 2016-04-12 |
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